Dimensioning system with guided alignment

ABSTRACT

A dimensioning system including a computing device running an alignment software program is disclosed. The alignment software uses range information from a range sensor in order to generate alignment messages. The alignment messages may help a user define a frame of reference and align the dimensioning system&#39;s range sensor for improved dimensioning performance.

FIELD OF THE INVENTION

The present invention relates to the field of dimensioning systems, andmore specifically, to a system and method for aligning a packagedimensioning system.

BACKGROUND

Generally speaking freight carriers calculate shipping costs based onpackage size and weight (i.e., volumetric weight). This helps preventlightweight packages that require a large amount of space from becomingunprofitable for the freight carriers.

When printing a shipping label for a package, a freight carrier employeeis required to enter the package's size and weight into a softwareapplication that uses this information to calculate the cost ofshipping. Typically, freight carrier employees derive this informationthrough hand measurements (e.g., with a tape measure) and may weigh thepackage on a scale. Hand measurements are prone to error, particularlywhen packages have an irregular shape. These errors may lead todissatisfaction and/or financial loss. For example, when a shippingcompany determines, after shipping costs are negotiated, that a packageis larger and/or heavier than reported by the customer, additional costsmay assessed. In addition, retailers that pass the shipping costs alongto customers typically assume the extra shipping costs associated withthese errors. As a result, automated dimensioning systems have beendeveloped to bring more accuracy to package volume calculation.

One such automated dimensioning system uses a light projector to projecta light pattern (e.g., point cloud) onto objects (e.g., packages) withina field of view. A range camera, physically offset from the lightprojector, creates a range image from the light pattern reflected fromthe packages. Software running on a computing device compares the lightpattern in the range image to some reference (e.g., a reference imagetaken during calibration). Through this comparison, the dimensions of apackage may be derived.

In order to dimension a specified size range (e.g., a range of packagesizes) accurately, the dimensioning system may require a user toposition (i.e., align) the range sensor into a particular pose (i.e.,height and orientation). This positioning typically takes place duringthe installation of the dimensioning system. During positioning the poseis computed relative to a reference (i.e., ground) plane that istypically defined prior to positioning. The process of selecting thereference plane and positioning the range sensor is not easily handledby a typical user, but poorly installed range sensors may result indimensioning errors or the inability to dimension. Therefore, a needexists for a method to assist the user with the selection of a referenceplane and the positioning of a range sensor to ensure good performanceof the dimensioning system.

SUMMARY

Accordingly, in one aspect, the present invention embraces a packagedimensioning system including a range sensor for capturing a series ofrange images of the range sensor's field of view. The system alsoincludes an adjustable range-sensor support to physically support andposition the range sensor in a target pose. A computing device,communicatively coupled to the range sensor, is capable of executing anadjustment software program, which provides adjustment messages tofacilitate the adjustment of the range sensor. The adjustment softwareprogram configures the computing device to receive the series of rangeimages, process the series of range images to produce the adjustmentmessages, and transmit the adjustment messages to a display. The displayis communicatively coupled to the computing device and displays theseries of range images and the adjustment messages.

In another aspect, the present invention embraces a computer implementedmethod for generating adjustment messages to facilitate the positioningof a range sensor for dimensioning. The method includes the step ofrecording range images onto a computer-readable storage medium. Themethod also includes the step of reading the range images from thecomputer-readable storage medium. In addition, the method includesprocessing the range images to derive a result. The method furtherincludes the step of generating adjustment messages based on the result.

The foregoing illustrative summary, as well as other exemplaryobjectives and/or advantages of the invention, and the manner in whichthe same are accomplished, are further explained within the followingdetailed description and its accompanying figure (i.e., fig.) set.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 schematically depicts an exemplary range sensor's stereoarrangement of a pattern projector of a range camera for capturing rangeinformation as a pixel displacement.

FIG. 2 graphically depicts an exemplary dimensioning system including aplatform and an object for dimensioning.

FIG. 3 schematically depicts an exemplary dimensioning system.

FIG. 4 schematically depicts a flowchart of an exemplary adjustmentsoftware program.

DETAILED DESCRIPTION

The present invention embraces a dimensioning system to measure items,such as packages for shipment. The dimensioning system typically uses arange sensor, a computing device, and a display for this measurement.The range sensor may be an optical system that acquires informationabout a field of view or could use another range sensing modality (e.g.,ultrasonic). The optical system requires a user to place an item withinthe system's field of view for measurement and is very easy to use. Forthe system to give best results, however, the range sensor should bepositioned in a range-sensor pose with respect to a frame of referenceshared by the package that closely matches a target pose (e.g., below anadjustable threshold value of pose difference). The target poserepresents the desired range sensor's position (e.g., height, pitch,roll, and/or yaw) with respect to the frame of reference that ensuresgood dimensioning performance. The target pose is chosen to allow therange sensor to obtain accurate dimensioning results for a given rangeof package sizes. For example, a target pose may be established tocontain the largest package to be dimensioned, while also ensuring thatthe smallest package may be resolved sufficiently for accuratemeasurement. The target pose is also chosen based on the range sensor'sresolution, field of view, and/or other limitations (e.g., specularreflections, multipath interference, and/or mixed pixel responses).Similarly, a target pose may be chosen to minimize depth differencesbetween a foreground package and clutter (e.g., background clutter). Thetarget pose may be stored on a computer-readable medium (e.g.,non-transitory memory) communicatively coupled to the computing deviceand is typically set once for a particular application. In certainscenarios, however, this target pose could adjustable. For example, anold target pose could be replaced with a new target pose, or in anotherembodiment, target poses could be selected by a user to match aparticular dimensioning application. For example, a user might want toreplace the range sensor with a new range sensor that has a different,sensing modality, resolution, and/or field of view. Here the user couldupdate the target pose to match the new range sensor. Alternatively, theuser might want to accommodate a new range of package sizes. Here theuser could update the target pose to meet the requirements of the newrange of package sizes.

The mathematical representation of a physical pose requires a frame ofreference. This frame of reference may be defined with a specifiedsurface (e.g., planar surface) or a line. Alternatively, the frame ofreference may be established with a set of 3D points that are arrangedin some known way. For example, a pose may be calculated relative to acylinder placed in front of the camera. Typically, however, a planarsurface within the field of view, selected by a user, establishes theframe of reference. For example, the surface that the measured item(e.g., package) rests on during the measurement (e.g., scale orcounter-top) may be chosen to serve as the reference surface (i.e.,platform). In this way, the orientations of the range-sensor pose andthe target pose (each relative to the frame of reference) can be derivedmathematically and compared (e.g., compared by rotation matrix oraxis-angle representation). For example, rotation vectors, with respectto the frame of reference, could be derived for each pose usingRodrigues' rotation formula. The angle between the two rotation vectorscould then be computed and compared to obtain the difference between therange-sensor pose and the target pose (i.e., pose difference).

The process of establishing the platform and aligning the range-sensorpose with a target pose may be made easier through the use of software(e.g., one or more executable files, libraries, and/or scripts) togenerate guidance advice for sensor alignment. Here, the adjustmentsoftware (i.e., adjustment software program) receives range images fromthe range sensor and produces feedback (i.e., adjustment messages) tohelp a user align the range sensor.

Range images are typically single-channel (e.g., gray scale) images thatrepresent the distance between the range camera and the portion of thefield of view represented by a pixel. Using these range images, theadjustment software may detect planar surfaces using an algorithm. Forexample, a random sample consensus (i.e., RANSAC) algorithm may identifyplanar surfaces within the range sensor's field of view. In the casewhere more than one planar surface is detected within the range camera'sfield of view, each planar surface may be indicated in a visual imagepresented on a display. In one possible embodiment, each planar surfacemay be indicated by an overlay (e.g., semi-transparent and/or coloredoverlay) image superimposed on the range image and presented on thedisplay. In other possible embodiments, the reference surface mayotherwise highlighted (e.g., an outline). A prompt, generated by theadjustment software, may query a user to indicate which planar surfaceshould be established as the reference surface (i.e., ground plane).Once the ground plane (i.e., platform) is established, the adjustmentsoftware may use the range image to compute the range camera's heightand orientation (i.e., roll, pitch, and/or yaw) with respect to theground plane.

During range sensor alignment (e.g., during installation of a packagedimensioning system) the adjustment software may use the computed rangesensor height and orientation to provide adjustment messages. Theseadjustment messages include indications of the necessary adjustments inorder to align the range sensor's physical pose with the target pose.This feedback may be audible or visual. Visible messages could be textmessages or graphical images displayed alone, in addition to, and/orsuperimposed on other images (e.g., range images, color images, orpoint-cloud images). By following these adjustment messages, a user mayadjust the range-sensor support (e.g., adjustable tripod mount, polemount, ceiling mount, and/or wall mount) to move the range sensor closerto the target pose. Many adjustment messages may be generated during thealignment process. In one possible embodiment, the process of analyzingrange images and providing alignment messages (e.g., “move camera up”)may continue iteratively until the range sensor is aligned with thetarget pose. Once aligned, the adjustment software may provide anadjustment message indicating that the range sensor is in position,indicating that the user should stop adjusting and secure the support.In another possible embodiment, the software may provide alignmentmessages that indicate the alignment of the range-sensor pose with thetarget pose in qualitative terms (e.g., good, better, or best). In stillanother possible embodiment, the software may simply provide real-timealignment information (e.g., pose difference results in numerical form)and allow the user to decide the ultimate alignment criteria.

While the adjustment software is typically used during the installationof the package dimensioning system, it may also be used periodicallyafter the installation. For example, the adjustment software program maybe configured to periodically check the range sensor's pose and comparethis with the target pose. If the difference between the two poses(i.e., pose difference) is above some threshold value (e.g., from amisalignment caused by mechanical movement or vibration), the guidancesoftware may provide messages to alert a user that the range sensor isno longer in alignment and that an adjustment is necessary.

The alignment process may happen in real-time with the display renderingreal-time range images, while simultaneously displaying adjustmentmessages. In one embodiment, for example, the adjustment software mayguide the user to first adjust range sensor's height and then adjust itsorientation (i.e., roll, pitch, and/or yaw) separately and sequentially.In another embodiment, the software may accommodate a user to jointlyadjust the range sensor's height and orientation simultaneously.

Three-dimensional (i.e., 3D) sensors (e.g., range sensors) can beutilized effectively in dimensioning applications. The recent advent ofrelatively low-cost range sensors that can detect and displaythree-dimensional information has afforded greater opportunity forimplementing automated dimensioning on a wider scale. Consequently, thepackage-dimensioning system disclosed here may include a range sensor toacquire a two-dimensional gray scale image for conveying the range on apixel by pixel basis (i.e., range image). In an exemplary range image,darker pixels may indicate a point that is a shorter distance away fromthe range sensor than points represented by lighter pixels.

In the embodiment shown in FIG. 1, the range sensor includes a projector1 and a range camera 2. The projector 1 may radiate a light pattern ontoan item 4 within a field of view 3. The reflected light pattern 6 fromthe item may be imaged and detected by the range camera 2. If the item'srange 7 is changed then the range camera may sense this change as adisplacement 5 in detected light pattern. A processor within the rangesensor may convert this range information into a range image. In thisway the pattern projector and range camera may together help to producea range image. The projector 1 and the range camera 2 are positionedcollinearly and are codirected towards the same field of view (i.e., arepositioned in a stereo arrangement). The light from the projector (e.g.,the point cloud) may be visible but is typically invisible to the humaneye. The range camera is sensitive to this light. In some embodiments,the range sensor also includes a color (i.e., RGB) camera that issensitive to visible light and which shares the field of view 3 with theprojector and range camera. This color camera may be used to displayimages for a user that are easily interpreted and less confusing thanthe gray scale range images or point cloud images. In another possibleembodiment, the range images may be displayed during the alignmentprocess. In yet another possible embodiment, the raw images includingthe projected light pattern (point cloud images) may be displayed duringthe alignment process.

An exemplary package dimensioning system is graphically shown in FIG. 2.Here the range sensor 10 is physically supported and positioned by therange-sensor support 11. The support helps configure the range-sensorpose which is defined by the range sensor's height 12 and orientation.The orientation may include the range sensor's pitch 13, yaw 14, and/orroll 15. A user may configure the range-sensor pose to match a targetpose through the use of an adjustable range-sensor support 11. Thissupport is shown in this embodiment as a tripod, though other supportmechanisms (e.g., pole-mount, wall-mount, or ceiling-mount) may be used.An adjustment software program executed by a computing device 16 maydisplay adjustment message on a display 13. The range-sensor pose andthe target pose are relative to a platform 18 (i.e., reference plane orground plane) that a package 17 is placed on for dimensioning. Theplatform may be selected by a user from a plurality of planar surfacesdetected within the field of view before the poses are calculated.

The schematic of the package dimensioning system including a computingdevice 24 for package dimensioning is shown in FIG. 3. Here a rangesensor 20 includes a pattern projector 27 for creating a light patternthat can be imaged by the range camera 22 and mathematically transformedinto a range image that is transmitted from the range sensor 20 to aprocessor 23 integrated in the computing device 24 and communicativelycoupled to the range sensor. The processor may store the range image ina computer-readable storage medium 25. Adjustment software stored in thestorage medium 25 may configure the processor 23 to execute the programsteps required for generating the adjustment messages necessary tofacilitate the positioning of the range sensor 20 for dimensioning. Theprocessor may transmit the adjustment messages to a display 26. Thesemessages may be displayed along with an image of the range sensor'sfield of view. This image of the field of view may be the range camera's22 image or may be a color image created by a color camera 21 configuredwith the same field of view as the range camera 22. The color camera isoptional but may enhance the user's experience, as these images may beeasier to understand than the gray scale range images.

As shown in FIG. 4, the adjustment software program 36 operates on rangeinformation (e.g., range images 31) to produce some feedback information(e.g., adjustment messages 39). A flowchart illustrating the method forgenerating adjustment messages to facilitate the positioning of a rangesensor for package dimensioning is shown in FIG. 4. The range sensor 30produces a range image 31. The software analyzes the range image todetect planar surfaces within the field of view. A user may then beprompted to select a reference plane (i.e., platform) from the detectedplanar surfaces. Alternatively, the software may detect and select aplatform automatically. Once the platform 32 is detected, a target pose33 may be computed based on a stored pose 34. The stored poseinformation may be information based on the range camera's field ofview, the range of expected package sizes, and/or the resolution of therange image. This information may be stored in the computing device'snon-transitory, computer-readable storage medium (e.g., hard drive). Theplatform 32 may also be used to mathematically compute the range-sensorpose 35 from the range image 31 and the platform 32. Mathematically apose may be defined as a vector relative to the platform 32. Theadjustment software program 36 then computes the difference between thetarget pose 33 and the range-sensor pose 35 to determine a posedifference 37 (e.g., vector difference). If the pose difference is zero(or below some threshold value) then the camera is considered aligned,however if the pose difference is above a threshold value, then adesired action 38 to minimize the pose difference is computed. Based onthe desired action 38, an adjustment message 39 is created. Thisadjustment message is then transmitted with the range camera's image tothe display 40 for viewing. The adjustment message could be a textmessage or a graphical image. In one possible embodiment an arrowgraphic indicating the direction to move the range sensor 30 could beoverlaid with the range image 31 on the display 40. In anotherembodiment the adjustment message could provide quantitativemeasurements (e.g., move camera up 10 cm). In another possibleembodiment the adjustment messages may be audio messages transmitted toa speaker for broadcast.

To supplement the present disclosure, this application incorporatesentirely by reference the following commonly assigned patents, patentapplication publications, and patent applications:

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In the specification and/or figures, typical embodiments of theinvention have been disclosed. The present invention is not limited tosuch exemplary embodiments. The use of the term “and/or” includes anyand all combinations of one or more of the associated listed items. Thefigures are schematic representations and so are not necessarily drawnto scale. Unless otherwise noted, specific terms have been used in ageneric and descriptive sense and not for purposes of limitation.

1. A dimensioning system comprising: a range sensor for capturing rangeimages of a field of view; an adjustable range-sensor support tophysically support and position the range sensor in a range-sensor pose;a computing device communicatively coupled to the range sensor, thecomputing device capable of executing adjustment software; wherein saidadjustment software generates adjustment messages to facilitate theadjustment of the range-sensor pose, the adjustment software configuringthe computing device to: (i) receive the range images, (ii) compute,using the range images, a pose difference, (iii) generate, based on thepose difference, adjustment messages, and (iv) transmit the adjustmentmessages to a display communicatively coupled to the computing device.2. The dimensioning system according to claim 1, wherein the adjustmentsoftware generates adjustment messages until the pose difference isminimized below an adjustable threshold value.
 3. The dimensioningsystem according to claim 1, wherein the range sensor comprises a stereoarrangement of (i) a pattern projector for projecting a light patternwithin a field of view and (ii) a range camera for capturing images ofthe reflected light pattern.
 4. The dimensioning system according toclaim 1, wherein the light pattern is invisible.
 5. The dimensioningsystem according to claim 1, wherein the range sensor comprises a colorcamera for capturing color images of visible light within the field ofview.
 6. The dimensioning system according to claim 1, wherein theadjustment software further configures the computing device to detectplanar surfaces in the range images.
 7. The dimensioning systemaccording to claim 6, wherein the adjustment messages compriseindications for a user to select a platform from the detected planarsurfaces.
 8. The dimensioning system according to claim 1, wherein thepose difference comprises a difference between the range-sensor pose anda target pose.
 9. The dimensioning system according to claim 8, whereinthe target pose is stored on a non-transitory computer-readable storagemedium communicatively coupled with the computing device.
 10. Thedimensioning system according to claim 8, wherein the target pose isadjustable.
 11. A method, implemented by a computer, for generatingadjustment messages to facilitate the positioning of a range sensor, therange sensor communicatively coupled to the computer and capable ofgenerating range images, the method comprising: recording the rangeimages from the range sensor onto a computer-readable storage medium;reading the range images from the computer-readable storage medium;processing the range images to derive a result; and generatingadjustment messages based on the result.
 12. The method according toclaim 11, wherein the step of processing comprises identifying at leastone planar surface in at least one range image.
 13. The method accordingto claim 12, wherein the step of processing comprises (i) computing arange-sensor pose and a target pose and (ii) comparing the range-sensorpose to the target pose to obtain a pose difference.
 14. The methodaccording to claim 13, wherein the adjustment messages compriseinstructions for physically adjusting the range sensor in order tominimize the pose difference.
 15. The method according to claim 11,wherein the range sensor comprises a projector for projecting a lightpattern in a field of view and a range camera for detecting the lightpattern in at least part of the field of view, wherein the projector andthe range camera are in a stereo arrangement.
 16. The method accordingto claim 11, wherein the adjustment messages comprise range images withsuperimposed graphics and/or text.
 17. The method according to claim 11,wherein the range sensor comprises a color camera.
 18. The methodaccording to claim 17, wherein the adjustment messages comprise colorimages with superimposed graphics and/or text.
 19. The method accordingto claim 11, wherein the adjustment messages comprise audio messages.20. The method according to claim 11, wherein the adjustment messagescomprise visual information displayed on a display communicativelycoupled to the computer.